Crane Collision Avoidance via Sensor-Based Path Planning
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Solution Overview
Problem
In factory environments, the movement of large objects like cranes poses a significant safety challenge due to potential collisions with individuals and other objects, exacerbated by limited human reaction time and visibility issues, particularly in noisy or complex settings.
Innovation Solution
A system comprising location sensors on movable cranes and objects within a facility, coupled with a controller that determines travel paths and generates alerts to prevent collisions, using technologies like RFID and safety range sensors for real-time guidance and collision avoidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual spotting and guidance is used for crane movement, then collision avoidance can be achieved through human observation, but productivity decreases due to area shutdowns and loss of time due to limited human reaction time
Solution Approach 1:
The patent replaces the manual mechanical observation system with an automated electronic sensor system. Location sensors on the crane and objects, combined with a controller, automatically detect positions and predict collision risks, eliminating the need for human spotters and area shutdowns while maintaining or improving collision avoidance reliability.
Solution Approach 2:
The controller performs preliminary collision risk assessment by determining the direction of travel and predicting potential intersection regions before actual contact occurs. This anticipatory approach allows the system to alert operators in advance, enabling preventive action rather than reactive response.
2Reliability
If manual spotting is used to guide crane movement, then collision risks can be monitored, but loss of time increases due to area shutdowns and human reaction time limitations
Solution Approach 1:
The system replaces manual monitoring with automated sensors and controllers that continuously track crane and object positions without requiring area shutdowns. The electronic monitoring system operates uninterrupted, eliminating time loss associated with manual safety protocols.
Solution Approach 2:
The controller acts as an intermediary between the crane's location sensor and the alarm device, processing location data and automatically determining collision risks without human intervention. This automated mediation eliminates the need for human spotters to physically monitor and report conditions.
3Reliability
If human operators manually monitor crane movements, then collision risks can be identified, but measurement precision decreases due to limited human speed to process warnings and complexity of visible and audible information
Solution Approach 1:
The patent replaces human sensory and cognitive processing with electronic sensors and computational algorithms. The location sensors precisely measure crane and object positions, while the controller's algorithms accurately determine direction of travel and predict intersection regions, achieving superior detection accuracy compared to human operators.
Solution Approach 2:
The system creates an electronic copy of the physical environment through location sensors that continuously track the positions of the crane and all objects. This digital representation allows the controller to analyze spatial relationships and predict collisions with high precision without the limitations of human perception.
Data Source
AI summary
Systems and methods for object guidance and collision avoidance are provided. One system includes a location sensor disposed on a movable crane. The system also includes a plurality of sensors disposed on a plurality of objects within a facility. The system further includes a controller having a receiver for monitoring signals transmitted from the location sensor disposed on a movable crane and the plurality of sensors disposed on a plurality of objects within the facility. The controller is configured to generate a travel path for the movable crane to move an object coupled with the movable crane based on the one or more intersection regions and generate an output signal to an alarm device to provide an alert, when at least one object of the plurality of objects is within a predetermined proximity of at least the object being moved by the crane.